U.S. patent number 3,701,964 [Application Number 05/069,555] was granted by the patent office on 1972-10-31 for flat cable electrical wiring system.
This patent grant is currently assigned to Lockheed Aircraft Corporation, Burbank, CA. Invention is credited to Michael J. Cronin.
United States Patent |
3,701,964 |
|
October 31, 1972 |
FLAT CABLE ELECTRICAL WIRING SYSTEM
Abstract
A flat cable electrical wiring system including a number of flat
electrical cables and a terminal junction assembly electrically
connecting selected cable conductors. The terminal junction
assembly has a terminal board mounting projecting electrically
isolated terminal pins receiving apertured terminals on the cable
conductors and retaining means for retaining the terminals on the
terminal pins. Two cable configurations are disclosed, one having
flat conductors whose terminals are attached in a fixed geometric
pattern directly to one end of the flat cable sheath and the other
having round conductors whose terminal ends extend beyond the ends
of the cable sheath. A variety of terminal junction assemblies are
disclosed including one in which selected cable conductors are
electrically connected by a flexible programmable circuit member or
plug having terminal pins engaging elements electrically connected
by programmable circuit means in a manner which permits wiring
changes without major modification of the basic wiring system by
substitution of one program circuit member for another. In another
disclosed terminal junction assembly, selected cable conductors are
electrically connected by engagement of their terminals over common
terminal pins. The junction assemblies may be arranged for
electrical interconnection of flat-to-flat or flat-to-round
conductor cables, electrical interconnection of flat cable and
existing conventional wiring systems, and for testing and
monitoring of the individual wiring circuits entering the
junction.
Inventors: |
Michael J. Cronin (Sherman
Oaks, CA) |
Assignee: |
Lockheed Aircraft Corporation,
Burbank, CA (N/A)
|
Family
ID: |
22089773 |
Appl.
No.: |
05/069,555 |
Filed: |
September 4, 1970 |
Current U.S.
Class: |
439/45; 439/77;
361/803; 174/261; 439/492; 439/49 |
Current CPC
Class: |
H01R
12/774 (20130101); H01R 12/79 (20130101); H05K
3/361 (20130101); H05K 1/0286 (20130101) |
Current International
Class: |
H05K
1/00 (20060101); H05K 3/36 (20060101); H01b
007/08 (); H01r 029/00 (); H05k 001/04 () |
Field of
Search: |
;339/17R,17F,17L,17M,17N,18R,18B,18C,59R,59M,60M,61M,65,66,75R,75MP,176M,176MP,176MF,75M,92,150
;174/68.5 ;317/101,99 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
article From Electronic Design Magazine, Oct. 28, 1959, pgs. 36-39,
.
"Making the Most of Flat Cables," by G. E. Smith & Wm.
Richter..
|
Primary Examiner: Marvin A. Champion
Assistant Examiner: Terrell P. Lewis
Attorney, Agent or Firm: George C. Sullivan Ralph M.
Flygare
Claims
1. A flat-cable electrical wiring system comprising: first and
second flat multiconductor electrical cables wherein the electrical
conductors of each of said cables are disposed in side-by-side
relationship and have apertured terminal means on the ends thereof;
a terminal board mounting a set of projecting terminal pins
engaging said conductor terminal means, the conductor terminal
means of said first flat cable being engaged over a first group of
said terminal pins and the conductor terminal means of said second
flat cable being engaged over a second group of said terminal pins;
an interchangeable programmable circuit means mounting a first
group of electrically conductive elements engaging said first group
of terminal pins and a second group of electrically conductive
elements engaging said second group of terminal pins; circuit
conductor means electrically connecting selected elements of said
element groups; and, retaining means releasably retaining said
terminal means on said terminal
2. A flat-cable electrical wiring system as defined in claim 1
including: a third flat cable having conductor terminal means
engageable over the terminal pins of both said pin groups in a
manner such that the conductors of said first cable are
electrically connected to certain conductors of said third cable
and the conductors of said second cable are electrically
3. A flat cable electrical wiring system as defined in claim 1
wherein: said retaining means comprises a relatively firm resilient
compression pad overlying said terminal board, and means for
pressing said pad toward said terminal board to retain said
conductor terminal means in firm electrical
4. A flat cable electrical wiring system as defined in claim 3
wherein: said compression pad includes electrically conductive
sockets receiving said terminal pins, and said sockets are exposed
at the outer side of said pad to provide terminal connections for
external circuit monitoring
5. A flat-cable electrical wiring system as defined in claim 3
wherein: said programmable circuit means comprises a programmed
circuit member between said terminal board and said compression pad
for electrically interconnecting selected terminal pins, said cable
conductor terminals are disposed between said programmed circuit
member and said compression pad so that said programmed circuit
member is urged toward said terminal board to retain said conductor
terminals in firm electrical contact with said
6. A flat cable electrical wiring system as defined in claim 5
wherein: said terminal pins extend through and beyond the side of
said programmed circuit member remote from said terminal board;
and, said compression pad includes electrically conductive sockets
receiving the extending ends of said terminal pins and providing
terminals for external
7. A flat cable electrical wiring system as defined in claim 3
wherein: said compression pad seats directly against said terminal
board and cable conductor terminals for retaining the latter in
firm electrical contact
8. A flat cable electrical wiring system as defined in claim 7
wherein: the side of said compression pad facing said terminal
board has projecting annular shoulders about said terminal pins
which bear against said cable conductor terminal means and provide
intervening clearance spaces for conventional wiring having
terminals engageable over said terminal pins.
9. A flat-cable electrical wiring system comprising: first and
second flat multiconductor electrical cables wherein the electrical
conductors of each of said cables are disposed in side-by-side
relationship and have apertured terminal means on the ends thereof;
a terminal board mounting a set of projecting terminal pins
engaging said conductor terminal means, the conductor terminal
means of said first flat cable being engaged over a first group of
said terminal pins and the conductor terminal means of said second
flat cable being engaged over a second group of said terminal pins;
an interchangeable program circuit means mounting a first group of
terminal pin sockets receiving said first group of terminal pins
and a second group of terminal pin sockets receiving said second
group of terminal pins; circuit conductor means electrically
connecting selected sockets of said socket groups; and, junction
retaining means for releasably clamping said terminal board and
said program circuit means together with said conductor
terminals
10. A flat-cable electrical wiring system comprising: first and
second flat multiconductor electrical cables wherein the electrical
conductors of each of said cables are disposed in side-by-side
relationship and have apertured terminal means on the ends thereof;
a terminal board mounting a set of projecting terminal pins
engaging said conductor terminal means, the conductor terminal
means of said first flat cable being engaged over a first group of
said terminal pins and the conductor terminal means of said second
flat cable being engaged over a second group of said terminal pins;
and, an externally accessible, interchangeable programming plug
including a first group of programming pins engaging said first
group of terminal pins, a second group of programming pins engaging
said second group of terminal pins, and circuit means electrically
connecting selected
11. A flat-cable electrical wiring system as defined in claim 10
including: a junction box enclosing said terminal board; and
wherein: said programming plug comprises a housing mounting said
programming pins and enclosing said circuit conductor means; said
junction box has wall openings through which said programming pins
are insertable to engage said terminal pins; and, said plug housing
has a removable cover which is removable to provide
12. A flat-cable electrical wiring system for interfacing with a
conventional separate, round-conductor, wiring system, comprising:
a flat electrical cable comprising a plurality of ribbon-like
electrical conductors disposed in side-by-side relationship, and
having apertured terminals on the ends of each of said conductors;
a terminal junction means comprising a terminal board mounting a
set of terminal pins which project beyond opposite sides of the
board to provide at one side of the board flat cable terminal pins
over which engage said cable conductor terminals and at the
opposite side of the board, terminal pins for connection to said
conventional round-conductor wiring; and, retaining means retaining
said cable conductor terminals on said cable
13. A flat cable electrical wiring system as defined in claim 12
wherein: said cable terminal pins comprise smooth cylindrical pins
and said
14. A terminal junction assembly for a flat cable wiring system
comprising: a terminal board mounting projecting electrically
isolated terminal pins; a resilient compression pad overlying said
terminal board; means for urging said compression pad into
engagement with said terminal board; a program circuit member
interposed between said terminal board and said compression pad;
electrically conductive sockets carried by said program circuit
member for receiving said terminal pins; and, circuit means
electrically interconnecting selected sockets and
15. A terminal junction assembly as defined in claim 14 wherein:
said terminal pins extend through and beyond the side of said
program circuit member remote from said terminal board; and, said
compression pad includes electrically conductive sockets receiving
the
16. A terminal junction assembly for a flat cable wiring system
comprising: a terminal board mounting projecting electrically
isolated terminal pins; and, a programmable interchangeable circuit
means comprising a plurality of electrically conductive elements
engaging corresponding terminal pins, and a plurality of circuit
conductors electrically interconnecting
17. A terminal junction assembly as defined in claim 16 wherein:
said conductive elements comprise sockets receiving said terminal
pins.
18. A terminal junction assembly as defined in claim 16 wherein:
said interchangeable means comprises a programming plug and said
conductive elements comprise projecting pins on said plug
engageable with said
19. A terminal junction assembly as defined in claim 18 including:
a junction box enclosing said interchangeable circuit means and
having wall openings aligned with said terminal pins; a housing
containing said circuit means and having a cover which is removable
to provide access to said circuit means for changing the programmed
electrical connection of said plug pins; and wherein said
projecting pins on said plug are insertable through said junction
box wall openings into electrical contact with said terminal
20. A programming plug for a flat cable wiring system, comprising:
a housing; pins projecting externally from one wall of said
housing; circuit means within said housing electrically connecting
selected pins; and, a cover on said housing which is removable to
provide access to said circuit means for rearranging said circuit
means to interconnect pins other than said selected pins.
Description
This invention relates generally to electrical wiring systems and
more particularly to a flat cable electrical wiring system.
Prior Art
A relatively recent innovation in the field of electrical wiring
systems is the so-called flat electrical cable, referred to also as
a tape cable. Such a flat cable has a relatively thin flat
strip-like sheath of plastic or other suitable electrical
insulating material containing a group of electrical conductors
arranged side by side. Each conductor has exposed end terminals at
the ends of the sheath through which electrical contact is made
with the conductor. Flat cables of this kind have two basic forms
referred to as flat conductor-flat cable and round conductor-flat
cable. As the name implies, a flat conductor-flat cable has
electrical conductors in the form of thin metal strips of
rectangular cross section. Similarly, a round conductor-flat cable
comprises a plurality of insulated electrical conductors of
circular cross section, in a contiguous side-by-side
arrangement.
Flat electrical cables have many advantages over conventional round
cables. These advantages are well known to those versed in the art
and need not be repeated here. Suffice it to say that flat cable
electrical wiring systems are gaining wide-spread use in many
installations, particularly aircraft wiring installations. In many
of these applications, the adoption of a flat-cable wiring system
requires the utilization of a total-system concept consisting of
appropriate component assemblies, such as specialized terminal
junctions, to provide effective interfaces between the flat-cable
system and the existing equipment and wiring systems. Another
requirement which a flat cable wiring system must satisfy,
particularly in the aircraft installations, is the capability of
monitoring, testing and re-routing wiring circuits.
The present invention provides a flat-cable electrical wiring
system, and component assemblies therefor, which satisfies the
above-stated system requirements. According to one of its aspects,
the invention provides a wiring system including a number of flat
electrical cables having apertured terminals at the ends of the
cable sheath, and a terminal junction assembly electrically
connecting selected cable conductors. This junction assembly
includes a terminal board mounting projecting terminal pins (or, in
certain embodiments, a socket) over which engage the conductor
terminals and retaining means for releasably retaining the
conductor terminals on the terminal pins.
Two flat cable configurations are disclosed. One cable
configuration is a flat conductor-flat cable wherein the conductor
terminals are attached, in a fixed geometric arrangement matching
the corresponding terminal pin arrangement, directly to the flat
ends of the cable sheath. The terminal pin receiving holes in the
conductor terminals open through the sheath ends to permit
placement of the terminals over the terminal pins. The other cable
configuration is a round conductor-flat cable wherein the terminal
ends of the cable conductors extend a distance beyond the ends of
the cable sheath for independent positioning of the conductor
terminals over the terminal pins.
A variety of terminal junction configurations are disclosed. One
disclosed junction configuration is a programmable terminal
junction assembly for trunk-type wiring systems. This junction
assembly has a circuit board overlying the terminal board and
mounting sockets receiving the terminal pins. The "circuit board"
may comprise either a flexible or rigid insulating sheet which is
provided with programmable circuit conductor means which
electrically connect selected sockets and, thereby, the
corresponding terminal pins and cable conductors. The junction
retaining means clamps the terminal and circuit boards together
with the cable conductor terminals positioned between the boards in
such a way that the terminals and terminal pins are firmly retained
in electrical contact. This form of terminal junction assembly
permits wiring changes without major modification of the basic
wiring system by substitution of one circuit board for another.
Another disclosed terminal junction configuration is a multi-way
distribution junction assembly or "splitter". In this terminal
junction assembly, selected conductors of the several cables
entering the junction are electrically connected by placement of
their terminals over common terminal pins of the terminal board. By
way of example, the terminal junction assembly may be arranged to
electrically connect selected conductors of a first-entering cable
to the conductors of a second-entering cable and other conductors
of the first cable to the conductors of a third-entering cable. The
junction assemblies may be arranged for electrical interconnection
of flat-to-flat or flat-to-round flat cables as well as electrical
interconnection of flat cable and existing conventional wiring
systems and for testing and monitoring of the individual wire
circuits entering the junction.
FIG. 1 is an exploded view of a flat cable wiring system according
to the invention;
FIG. 2 is a section through the assembled wiring system;
FIG. 3 is an exploded view through a modified flat cable wiring
system according to the invention;
FIG. 4 is a section through the modified wiring system of FIG.
3;
FIG. 5 is an exploded view through a flat cable wiring system
according to the invention for interfacing with a conventional
wiring system;
FIG. 6 is a section through the assembled wiring system of FIG.
5;
FIG. 7 is an exploded view of a modified flat cable wiring system
for interfacing with a conventional wiring system;
FIG. 8 is a section through the assembled wiring system in FIG.
7;
FIG. 9 is a fragmentary enlargement of a portion of FIG. 8;
FIG. 10 is an exploded view of a modified programmable flat cable
wiring system according to the invention, and
FIG. 11 is a section through the assembled wiring system in FIG.
10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIGS. 1 and 2, there is illustrated a flat cable
electrical wiring system 10 according to the invention including
four flat electrical cables 12, 14, 16 and 18 and a terminal
junction assembly 20. Cables 12 and 14 are flat conductor-flat
cables. Cables 16 and 18 are round conductor-flat cables. Each
cable 12, 14 has a relatively thin flat strip-like sheath 22 of
plastic or other electrical insulating material containing a group
of thin flat strip-like conductors 24 arranged side by side. Each
flat conductor has an apertured end terminal 26 at each end. Each
end 22a of the sheath 22 of each cable 12, 14 is laterally enlarged
to allow passage through the terminal pins/sockets in the terminal
junction assembly. The conductor terminals 26 of each cable 12, 14
are attached, in a fixed printed-circuit arrangement, directly to
the ends 22a of the cable sheath in a manner such that the terminal
holes open through the sheath ends, as shown.
Each flat cable 16, 18 has a relatively thin flat strip-like sheath
28 of plastic or other electrical insulating material containing a
group of round conductors 30 arranged side-by-side. Each conductor
30 has an apertured terminal 32 at each end. The terminal ends of
the conductors 30 extend beyond the ends of the cable sheath 28, as
shown, whereby the conductor terminals 32 are independently
positionable. However, it is significant to note that the extending
conductor ends have different lengths such that the conductor
terminals tend to assume a particular geometric arrangement.
Terminal junction assembly 20 has a rectangular terminal board 34
mounting a set of projecting terminal pins 36. The base member 38
of the terminal board is constructed of an electrical insulating
material, and the terminal pins 36 are spaced from one another.
Accordingly, these pins are electrically isolated from one another.
Each terminal pin 36 has a stem 40 surrounded at its base by a
flange 42 which seats against the base member 38. While the
illustrated terminal board 34 has terminal pins on only one side,
it will become evident that both sides of the board may be provided
with pins. In this case, the terminal pins on one side of the board
will be electrically isolated from the terminal pins on the
opposite side of the board.
While the embodiment shown in FIGS. 1 and 2 employs projecting pins
36, it is to be understood that such pins may be replaced with
pin-receiving sockets if desired.
In the particular junction assembly 20 illustrated, the set of
terminal pins 36 are arranged in four groups 36a, 36b, 36c and 36d
along the four edges of the base member 38. The two flat cables 12,
14 extend from the two opposite edges of the terminal board 34
mounting the terminal pin groups 36a, 36b. The conductor terminals
26 of each latter cable engage over the adjacent group of terminal
pins 36, as shown. In this regard, it will be observed that the
fixed geometric arrangement of the conductor terminals 26 of each
cable 12, 14 matches the geometric arrangement of the terminal pins
of the adjacent pin group, such that the terminals may be engaged
over the pins in the manner shown. The two flat cables 16, 18
extend from the two opposite edges of the terminal board 34
mounting the terminal pin groups 36c, 36d. The conductor terminals
32 of each latter cable engage over the adjacent group of terminal
pins 36, as shown. In this regard, it will be observed that the
latter terminals have a general geometric arrangement matching
those of the adjacent pin groups. However, unlike the fixed
terminals of cables 12, 14, the terminals of cables 16, 18 are
independently positionable for engagement over the terminal
pins.
It should be understood that the four-sided geometry of the
terminal junction assembly 20 is exemplary only, and may be readily
modified to provide a lesser or greater number of cable interfaces.
Also, the particular combination of cable types shown and described
is merely exemplary and may be altered in as many permutations as
is appropriate to a given application.
The terminal junction assembly 20 electrically interconnects
selected conductors 24, 30 of the four flat cables 12, 14, 16, 18.
In this particular junction assembly, such selective
interconnection of the conductors is accomplished by a programmable
circuit member 44. This member may be constructed of either a rigid
or flexible material. To this end, the program circuit has a
rectangular configuration 46 of electrical insulating material
enclosing a set of electrically conductive apertured terminal pads
48 equal in number to the terminal pins 36. The program member 46
has approximately the same size and shape as the terminal board
base member 38 and the sockets 48 are arranged to mate with the
terminal pins 36. After the cable conductor terminals 26, 32 have
been placed over the terminal pins 36, the program circuit member
44 is placed over the terminal board 34 in such a way that the
terminal pins enter the apertured terminal pads 48. Program circuit
member 44 is provided with printed circuit conductors 50 which
electrically interconnects selected sockets 48 and, thereby, the
corresponding terminal pins 36 and cable conductors 24, 30.
Terminal junction assembly 20 is equipped with retaining means 52
for retaining the cable conductor terminals 26, 32 on and in firm
electrical contact with the terminal pins 36 by clamping the
terminal board 34 and circuit member 44 tightly together. Retaining
means 52 comprises a relatively firm resilient compression pad 54
of hard rubber or the like having the same rectangular shape and
size as the terminal board 34 and circuit member 44. This pad
mounts electrically conductive terminal pin sockets 56 equal in
number to and arranged in the same manner as the terminal pins 36
and circuit member terminal pads 48. Compression pad 54 is placed
on top of the circuit member 44 in a manner such that the terminal
pins 36 project into the pad sockets 56. In this regard, it will be
observed that the length of the terminal pins exceeds the thickness
of the circuit board, such that the pins project beyond the circuit
board for engagement in the compression pad sockets.
Overlying the compression pad 54 is a retainer plate 58. This plate
is attached to the base member 38 of the terminal board 34 by
screws 60 which extend through clearance holes in the compression
pad and program circuit member 46. It is significant to observe
that the retainer plate has a skeleton structure which is shaped to
avoid shorting contact of the plate with the compression pad
sockets 56. Retainer plate screws 60 are tightened to firmly clamp
together the terminal board 34, circuit member 44, and compression
pad 54. The cable conductor terminals 26, 32, which are interposed
between the terminal and circuit boards, are thereby urged into
firm electrical contact with the terminal pin base flanges 42. The
terminal junction assembly 20 is completed by a cover plate 62
which is fastened by screws 64 to the retainer plate 58.
The illustrated terminal junction assembly 20 has numerous unique
features and advantages. Thus, wiring changes may be made without
major modification of the basic wiring system by merely
substituting one programmed flexible or rigid circuit member 44 for
another. This feature has a distinct advantage in aircraft wiring
systems since any wiring changes which are necessitated in an
aircraft in service as a consequence of the addition, removal, or
change of wiring circuits may be accomplished by producing the
properly programmed circuit member and distributing the latter to
the current location of the aircraft.
Another feature of the illustrated terminal junction assembly 20
resides in its adaptability to checking and monitoring of
individual wire circuits. Thus, when the circuit board 44 is
removed, all circuits are isolated from one another and exposed for
complete check-out. This, then, is an important maintenance
feature. On the other hand, removal of the junction cover 62
exposes the compression pad sockets 56 for engagement by probes of
circuit monitoring instruments. Also, wire jumpers or "patch cords"
may be installed as a semi-permanent program circuit in lieu of
fixed program member, such as may be desired during development,
testing, or maintenance procedures.
It will be understood that while the illustrated wiring system has
two flat conductor and two round conductor flat cables, a present
flat cable wiring system may embody any number of cables in any
desired mix of flat and round conductor cables, as well as all flat
conductor or all round conductor cables. In this regard, it is
significant to recall that both sides of the terminal board 34 may
mount terminal pins 36 for receiving cable conductor terminals. It
will be understood that in this case, each side of the board will
be provided with a programmed circuit member 44, compression pad
54, retainer plate 58, and cover 62.
Turning next to FIGS. 3 and 4, there is illustrated a flat-cable
electrical wiring system 100 including three flat electrical cables
102, 104, 106 and a terminal junction assembly 108. The cables 102,
104, 106 are all shown to be flat conductor-flat cables which are
substantially identical to the earlier described cables 12, 14.
Each cable has conductors 110 within a flat sheath 112 provided
with apertured pad terminals 114 which are attached directly to the
flat ends of the sheath in such a way that the terminal holes open
through the sheath.
Terminal junction assembly 108 is designed to electrically connect
certain conductors 110 of cable 102 to the conductors of cable 104
and other conductors of cable 102 to the conductors of cable 106.
To this end, the terminal assembly comprises a terminal board 116
including a base member 120 of electrical insulating material
mounting a set of electrically isolated terminal pins 122 similar
to terminal pins 36. The conductor terminal pads 114 of cable 102
and the terminal pins 122 are equal in number and have the same
geometric arrangement to permit engagement of the latter conductor
terminals over all the terminal pins, as shown.
The conductor terminal pads 114 of cables 104, 106 are equal in
number to and are arranged to engage over different selected groups
of the terminal pins 122. In the particular wiring system
illustrated, for example, the terminal pins 122 are arranged in
four rows. The conductor terminal pads of cable 104 are arranged to
engage over two alternate rows of pins, and the conductor terminal
pads of cable 106 are arranged to engage over the two intervening
rows of pins. Each cable sheath 112 is apertured to receive the
intervening rows of pins, as shown. From this description, it will
be understood that the conductor terminal pads of of cable 104 and
one group of the conductor terminal pads of cable 102 engage over
one group of common terminal pins 122, whereby the corresponding
cable conductors are electrically connected. Similarly, the
conductor terminal pads of cable 106 and another group of the
conductor terminal pads of cable 102 engage over another group of
common terminal pins, whereby the corresponding cable conductors
are electrically connected. By appropriate geometric arrangement of
the terminal pads in cables 104 and 106, many viable configurations
of cable splitters can be provided.
Overlying the terminal board 116 is a relatively firm resilient
compression pad 124. In this instance, the compression pad has no
terminal pin sockets and the terminal pins 122 are dimensioned to
just project through the cable conductor terminal pads 114. The
compression pad 124 is compressed against the terminal board 116 by
a cover 126 attached to the board by screws 128. The conductor
terminal pads 114 are thereby retained in firm electrical contact
with the terminal pins 122 as in the first form of the invention.
While the compression pad 124 is devoid of terminal pin sockets, it
will be understood that such sockets may be provided on the pad for
the reasons stated earlier. The terminal pins 122 may also be
replaced by hollow terminal pins, having internal spring contacts,
to serve the same advantages previously described, as will be
apparent to those versed in the art.
FIGS. 5 and 6 illustrate a modified flat-cable wiring system 200
according to the invention which is designed to interface with a
conventional wiring system. This modified wiring system may be
utilized to electrically interconnect any number of flat electrical
cables with a conventional wiring system. For convenience, only a
single flat cable 202 is illustrated. This flat cable has a flat
sheath 204 containing a group of flat conductors 206 whose
apertured terminal pads 208 are attached directly to the ends of
the sheath, as in the earlier described flat conductor cables.
In addition to the flat cable 202, the wiring system 200 has a
terminal junction assembly 210 which is shown to be mounted on an
aircraft firewall 212. Junction assembly 210 includes a terminal
board 214 having a base member 216 of electrical insulating
material mounting a set of electrically isolated terminal pins 218.
In this instance, the terminal pins project through and beyond
opposite sides of the terminal board base member. The projecting
pin ends 218a at one side of the terminal board provide flat cable
terminal pins similar to those in the earlier described terminal
boards. The projecting pin ends 218b at the opposite side of the
terminal board are threaded to provide terminal pins for
conventional wiring.
Terminal board 214 is surrounded by a mounting frame 220 having
flanges 222 which overlie edge portions of the terminal board base
member 216. Frame 220 is attached to the firewall 212 by bolts 224
over an opening 226 in the wall in such a way that the edge
portions of the base member seat against the wall about the opening
and are clamped between the wall and the frame flanges 222. A
gasket 228 is interposed between the wall and base member. Terminal
board 24 is positioned in the frame so that its flat cable
terminals 218a project outwardly away from the firewall and the
conventional wiring terminals 218b project through the wall opening
226.
As in the earlier wiring systems of the invention, the flat cable
conductor terminal pads 208 have a fixed geometric arrangement
matching that of the flat cable terminal pins 218a. The conductor
terminals are engaged over the latter pins, as shown. Conductor
terminal pads 208 are retained on the terminal pins 218a by a
relatively firm resilient compression pad 230 having electrically
conductive sockets 232 receiving the protruding ends of the pins.
Compression pad 230 is urged against the terminal board, to retain
the conductor terminals 208 in firm electrical contact with the
base flanges of terminal pins 218a, by a retainer plate 234 secured
to the terminal board by a bolt 236. The head of this bolt seats
against the rear side of the terminal board and its shank extends
through the board, compression pad and retainer plate. A nut 238
threaded on the shank retains the parts in assembled relation.
Overlying the retainer plate is a cover 240 which is fastened to
the frame 220 by bolts 242.
As noted earlier, the illustrated flat cable wiring system is
designed to interface with a conventional wiring system. This
conventional wiring system includes conductors 244 having end
terminals 246 which are engaged over the threaded terminal pins
218b. Terminals 246 are retained on the terminal pins 218b by nuts
248. Programming or changing the electrical relationships of the
round to the flat wiring can be accomplished via the connection of
the round wires to the threaded terminal pins 218b.
The wiring system 200 obviously possesses the advantages of the
earlier described flat cable wiring systems, i.e., adaptability to
checking and monitoring of the individual wiring circuits.
FIGS. 7-9 illustrate a modified flat cable wiring system 300 for
interfacing with a conventional wiring system. This modified wiring
system has a terminal board 302 with upper flat cable terminal pins
303, a flat electrical cable 304, and a compression pad 306 similar
to and assembled in the same manner as those of wiring system 200
except that it has no terminal pin sockets. Also, pad 306 has lower
shoulder faces 307 about terminal pins 303 which press against the
cable terminals. Terminal board 302, the terminal end of cable 304
and compression pad 306 are contained within a hollow junction box
310 having a cover 312 fastened to the box by screws 314. The
terminal end of the flat cable is laterally enlarged to ease
passage of conductors through terminal pins 303. The terminal board
base member 318 rests on a shoulder 320 within the junction box
310. The circuit board 302, cable 304, and compression pad 306 are
firmly clamped between box cover 312 and shoulder 320. The lower
threaded conventional wiring ends or studs 322 of the terminal pins
303 are spaced from the bottom wall of the junction box 310, thus
to permit engagement over the studs of the terminals 324 of the
conventional wiring 326. The flat cable 304 and conventional wiring
326 enters the junction box through suitable openings, as
shown.
Turning to FIGS. 10 and 11, there is illustrated a modified flat
wiring system 400 including a programmable terminal junction
assembly 402 for electrically connecting selected conductors of
flat cables 404, 406 entering the junction assembly. Junction
assembly 402 has a junction box 408 having a cover 410 and side
openings through which the terminal ends of cables 404, 406 enter
the box. These cable ends are laterally enlarged to ease routing of
the conductors. Within the terminal box 408 is a terminal board 412
with flanged-terminal pins 414 over which the cable conductor
terminals 416 engage. A compression pad 418 is placed between the
junction box cover 410 and terminal board 412 for retaining the
conductor terminals 416 in firm electrical contact with the
terminal pins 414.
Terminal junction assembly 402 has an external circuit board in the
form of a programming plug 420. This programming plug includes a
housing 422 with a removable cover 424 and mounting programming
pins 426 which project through the bottom wall of the housing.
Selected pins 426 are electrically connected within the housing 422
by programmable circuit means 428. In this instance, the circuit
means comprise jumper wires which are secured to the pins 426 in a
manner such that the wires may be shifted from pin to pin to change
the programmed electrical connections of the plug 420 by removal of
the housing cover 424. If desired, however, other types of
programmable circuit means may be employed, such as replaceable
printed circuits.
The programming plug 420 is adapted for insertion into the junction
box 408 to electrically connect selected terminal pins 414 and
thereby the corresponding flat cable conductors. To this end, the
terminal pins 414 have sockets 430 for receiving the plug pins 426
and the junction box cover 410 and compression pad 418 have
openings 432, 434 through which the plug pins may enter the
terminal pin sockets, as shown. This externally programmed terminal
junction assembly has all of the advantages of the earlier
described programmable junction assembly and the additional
advantage that the junction wiring program may be changed by merely
changing programming plugs, or the programming circuit means of the
plug, without disassembling the terminal junction box 408.
Moreover, when the programming plug is removed, the terminal pins
414 are accessible for circuit check-out.
* * * * *